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Increased Efficiencies for Robotic Aseptic Syringe Filler/Capper

OEM Application Note: ESS Technologies’ new TaskMate robots with RABS enclosures benefit from controls and automation enhancements, as well as hygienically designed components.

The TaskMate Robotic Syringe Filler and Capper system integrates two Fanuc clean class LR Mate robots with RABS (Restricted Access Barrier System)
The TaskMate Robotic Syringe Filler and Capper system integrates two Fanuc clean class LR Mate robots with RABS (Restricted Access Barrier System)

It wasn’t that long ago that packaging robots focused on end-of-line functions, such as case packing and palletizing. In December, ESS Technologies introduced its TaskMate Robotic Syringe Filler and Capper. The system integrates two Fanuc clean class LR Mate robots with a Restricted Access Barrier System (RABS) from Skan to meet the stringent requirements for 503B sterile pharmaceutical compounding applications. ESS designed the system to increase production speeds and efficiency, reduce scrap and rework, and reduce overhead while protecting both products and employees from harm. The system can fill and cap up to 15 syringes/min.

The SF20 syringe filler is part of the TaskMate Robotic Systems brand. In operation, empty syringes are manually fed through a sterile rapid transfer port into the ESS-supplied vibratory hopper, dropping them gently onto a flex feeder with a powered, backlit, vibratory conveyor. A spreading tray/vibrating conveyor moves parts forward to a Fanuc 2D guidance vision system where the first LR Mate 200iD robot picks syringes one at a time. When no parts are available, the robot will turn the spreading tray on and signal the vibratory hopper to feed additional parts. Once the camera sees available parts again, the conveyor and vibratory hopper stops. The robot, which uses a custom-designed vacuum-style end-of-arm tool (EOAT), picks a syringe from the flex picker conveyor and transfers it to the filling station.

The filling system uses a stainless-steel, servo-driven volumetric pump, which is provided with an input connection to attach the filling nozzle to the product supply bag. A precise amount of liquid is dispensed from the bottom up. Caps are manually fed via a drawer that can be pulled out from the RABS to load and unload trays of caps. The second Fanuc LR Mate 200iD robot, which also uses a custom-designed vacuum-style EOAT, picks a cap from the tray and places it into the torque station. A servo-driven pick-and-place unit transfers the syringe from the fill station to the final torque station.

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